NWIPCM-1P User Manual
Contents
1. Rev 1 3 01 11 NWIPCM 1P SERIES USER MANUAL PHASE ANGLE SCR POWER CONTROL DRIVER BOARD FOR INDUCTIVE LOADS COPYRIGHT 201 1 NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual TABLE OF CONTENTS O AAA 2 2 DESCAPUO surcar add eee 3 Se EE Eeler de e A 3 3 1 Mounting Instruchons 4 O22 ie A PPP Pe 4 3 38 SCR Output Snubbers and Transient Protection nonnnannnennnannnnnnnnnnnnnonrnsnrennreennnnn 4 3 3 1 Commun Gi gei e cen ne ne a 4 3392 e AROMA es 4 PP 4 oo MOV MATN O PON PP 4 Sa VITO VV EY e E 5 A OPE o AP e 5 GEN WE Ge E ee EE 5 4 2 e GI Fusing arameo era 5 do Command INDUL saris cannot atea 5 4 4 PWM Command Input 5 4 4 1 Input Fail Safe Hrotechon 6 45 Line Voltage COMPENSATION ccoooccccccnnccccnnccncnnncnnnnononnnonannnonannnonannnonannnnnnnnnnnnnnonannnennns 6 4 5 1 Line Voltage Compensation Nominal Adiustment 6 E EE Late 6 4 6 1 GUNS LIME SOM OMI OG e E 7 ca SOW LAN COPEC o In e amend o OE O 7 AS A UA 7 4 8 1 Voltage Limit Adjustment Hrocedure 7 4 9 Current Feedback Current mm 8 4 9 1 CUCL LEE ee 8 49 2 C rentLimit Adjustment See T L escalas 8 4 10 Configuration Dipswitch A 9 A MOCO LEDS traca dia diana dotada dada ida 9 4 11 1 OA 9 dal 2 OCR lie DIV EE 9 Aids OUA 001 ELED aran aran narrada ee 9 4 11 4 LoagdFauhlEID 9 4 12 Three Phase Operation sosirii 10 o A en n 10 5 1 Load Fault OUT vU CC 10 2 ARAR CHE 10 O e lge SS OO sees cscs eo A 10 Te ENE CHC SOC CINCO ON2. 4 12 Three Phase Operation Three NWIPCM 1Ps can be used to control three poles of a three phase load for inside delta or grounded WYE configurations 5 Fault Outputs 5 1 Load Fault Outputs The open collector load fault output is energized when a load fault condition exists when the load fault led is on 5 2 Aux Alarm Outputs The Alarm output is a custom configured option 6 Current Retransmit Output The Current Retransmit output is designed to be a relative indication with 10 of full scale accuracy The output is 0 5V from 0 100 of the full scale load current Copyright 2011 NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual 7 Electrical Specifications 7 1 SCR Gate Drive Profile 1 2Amps Peak a lt x da E E HI or Re E S O N P 50uS Width Gate current maintained through conduction period SCR Gate Drive Profile 7 2 Input Specifications Command Inputs Input Impedance Response Time PWM Input Frequency PWM Input Level PWM Vinlow 20 PWM Vinhigh 20 CT Input Range External Potentiometer Res Command to Mains Isolation Command to SCR Drive Isolation 7 3 Output Specifications Control Range Output Linearity Line Voltage Comp Range Regulation Soft Change Period Current Limit Range Voltage Limit Range Ambient Temperature Range Power Supply Line Frequency Range SCR Gate Drive Characteristics Open Collector Alarm Outputs 0 5V Cu
3. 1 35 MAX Y i 2000 fil I AT 0 45 TO SNAP LOCK IN A 187 003 4 75 0 08 DIA HOLE IN A 031 078 0 79 1 98 PANEL THICKNESS NWIPCM 1 MOUNTING amp DIMENSIONS DC 080109 Copyright 2011 NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual 8 WIRING DIAGRAM SINGLE PHASE A COMMAND INPUTS _____ l PWM INPUT ANALOG INPUT POTENTIOMETER AUX ALARM OPEN COLLECTOR 28VDC 50mA MAX LOAD FAULT OPEN COLLECTOR 28VDC 50mA MAX NON ISOLATED PWM INPUT 0 5V CURRENT RETRANSMIT 4 20mA 0 10V H 24VPWM NOMINAL OUTPUT ADJUST CURRENT LIMIT ADJUST VOLTAGE LIMIT ADJUST p SCR 1 CONNECTIONS X D viele o o o o o o o o o oooo0oo0oo0oo0o0o0 ooondo oen ES m 00000 Go ci4 OO D OO O en jo J2 lesen NWIPCM ANG 1 le 08 ele A o DANGER HAZARDOUS E 12493 gt p L1 12 G LINE VOLTAGE SELECT CURRENT TRANSFORMER 0 200A 1000 1 0 400A 2000 1 L1 LOAD mmm de a cee emm cee a a emm a EXTERNAL SNUBBER REQUIRED FOR PROPER SCR TURN ON OFF DC 080109 9 Contact Information NuWave Technologies Inc 866 379 3597 www nuwaveproducts com Copyright 2011 NUWAVE TECHNOLOGIES INC
4. Seran teclea load deis 11 S E EA 11 7 2 Input Specifications 00nnenannnennenanenennnnnnnrrnnrnrnrnrenrrrrnnrrnnrrnenrrsnrrnnrrrnnrrnnrrrenrrnnrrnn 11 L CK el ele ee EE 11 7 3 1 Mechanical DIMENSIONS coooccocccccncocncoconononononcnoncnnnconononononnnnnnnnnnnnnnonanonancnnnnninos 12 8 WIRING DIAGRAM GINGLEDHAGE 13 9 Contact reide mk ds 13 1 Ordering Codes Copyright 2011 NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual Ordering Codes NWIPCM 1P Inductive Load Power Control Module Single Pole Phase Angle 120 or 240 PWR XSS Softstart Time seconds XSC Soft Change Time seconds 1 sec Soft Change is the default LIV Linear RMS Voltage ge Linear RMS Power is the default Example NWIPCM 1P 120 1SC Inductive Load Phase Angle Control Module RMS power output 120V PWR 1 sec soft change this is the default configuration if the NWIPCM 1P XXX is ordered 2 Description The NWIPCM 1P is a Phase Angle SCR Power Control Driver Board designed for use with high power back to back SCR modules driving resistive or inductive loads The power delivered to the load is proportional to the command input signal The gate drive technique used in the NWIPCM is DC drive for the greatest stability for firing inductive loads Features Provides true linear power or linear voltage output phase angle control Command input accepts 4 20mA 0 10V 0 5V Pot PWM Configurable line voltage comp
5. current 1 500 100A RMS 1 1000 200A RMS 1 2000 400A RMS 1 4000 800A RMS 1 5000 1000A RMS Other combinations of primary and secondary turns ratios may be used as long as the 200mA RMS and 5V peak of the CT input are not exceeded 4 9 2 Current Limit Adjustment Procedure The Current Limit is adjustable from 10 to 100 of the full scale current Setting the Current Limit potentiometer half way corresponds to a current limit of approximately 50 of full scale The best way to set the current limit is using a true RMS current clamp meter on the load circuit With the command input set to approximately 100 on startup turn the current limit pot fully CCW Then just turn the pot CW slowly until the desired max output on the clamp meter current is observed The output current will be limited to the read current within 5 of full scale Copyright 2011 NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual When the NWIPCM 1P is actively holding back or limiting the load current the RED LIM ON LED will become energized lf the current limit LED begins to blink the current transformer input is overloaded Overload occurs if the peak current goes beyond the ratings of the CT input This will affect the accuracy of the current limit and if the indicator blinks continuously the NWIPCM 1P module may become damaged 4 10 Configuration Dipswitch The configuration dipswitch is used for setting up the command input line voltage comp
6. LOAD POWER 0 81KW 20 4 5 1 Line Voltage Compensation Nominal Adjustment The nominal adjustment pot sets the nominal level of output for the current line voltage being measured This should be adjusted so that with 100 command applied the Output is just able to achieve full power 98 4 6 Soft Change Copyright 2011 NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual The soft change feature limits how quickly the output can change value For inductive loads such as transformers soft change is always required because it prevents inrush current associated with DC accumulation and saturation of the transformer Soft Change can be set on or off using the configuration dipswitch 7 The default setting is off Soft change times below or above one second are available and can be ordered by adding a XSC to the ordering code where X is the time in seconds 4 6 1 Current Limit amp Soft Change The current can be used with soft change If Current Limit and soft change are selected the 1 seconds or special ordered soft change time XSC will be applied with current limit 4 7 Soft Start The Soft Start feature ramps up to the command value over a period of approximately 1 second lf soft start is ordered the soft start time resets if the command value goes to zero less than 4 of the input range or power is cycled Soft start is useful on high inrush heaters such as Quartz Molybdenum Tungsten or Graphite heaters So
7. and input is designed to accept a signal from a PLC ora process temperature controllers SSR drive output This logic signal is used to generate a command setpoint The PWM input has two inputs PWM and PWMH The PWM input leg should be used for 5V logic drive The PWMH input leg should be used for 24V logic drive There are two dipswitch settings for the PWM input PWMF fast and PWMS slow The PWMF should be selected for 250Hz to 15KHz PWM The PWMS should be selected for 10Hz 100mS Cycle Time to 250Hz PWM signals The PWM input is not isolated from the other low voltage I O 4 4 1 Input Fail safe Protection lf the signal sent to the NWIPCM 1P s command input should become electrically open the control output will be forced to an off state 4 5 Line Voltage Compensation The NWIPCM 1P s line voltage compensation keeps the power constant on the load as the line voltage changes The line voltage is measured via the 120 or 240V power applied to the NWIPCM 1P module Line Voltage Compensation can be enabled or disabled using the configuration dipswitch The default setting is enabled Switch 3 is OFF To disable the Line Voltage Compensation set switch 3 to the ON position With a 10 drop in line volfage NWIPCM 1P load power drops less than 2 120V TKW 14 4 Ohm Load Without Line Voltage Compensation NWIPCM 1P Line Voltage Compensation 120VAC 120VA C 108VA C 108VAC 10 10 MAINS VOLTAGE IKW IKW
8. co LCBS 8 01 See the mechanical dimensions section for more details The PCB should be mounted at least 0 500 from any surface 3 2 Electrical Connections see the WIRING DIAGRAMS at the end of this document Make sure the module ordered is the correct module for the application before wiring Before wiring the module all Dip Switch settings for the command input and special features should be setup properly per the Dipswitch Configuration Section 3 3 SCR Output Snubbers and Transient Protection 3 3 1 Commutation Problems When an SCR or TRIAC is used to control an inductive load the load current lags the mains voltage When the device turns off at zero current the rate of rise of the reapplied voltage can retrigger the device and produce half cycling and blown fuses To limit this rate of rise and obtain reliable commutation an R C resistor capacitor snubber circuit should be connected in parallel with the SCR TRIAC 3 3 2 dv dt Problems When voltage transients occur on the mains supply or load of an SCR TRIAC it can cause the device to turn on unexpectedly due to the fast rate of rise of voltage dv dt This can result in false firing and half cycling of the load that can cause blown fuses when driving inductive loads An R C snubber circuit will help to limit the dv dt seen by the device and will produce more reliable firing 3 3 3 Snubber Sizing When an SCR TRIAC using an R C snubber turns on the capacitor is discharged t
9. ensation soft start and current limit Using a pen point gently push the switch up for on and down for off according to the setup outlined in the table below Commandinput 1 2 4 5 6 onv oer ol or oer OFF aoma Or or Or o oN um Or oer Or oer oN aw Or ol or oer oN PWM Fast or or o oer or C PWS Sow o oer om oer or Feature to Enable 3 7 8 None ON f Line Voltage Comp Enabled default OFF Soft Start Soft Change Enabled ON CurrentLimit ON 4 11 Indicator LEDs 4 11 1 Power LED The Green Power LED will illuminate when power is applied 4 11 2 SCR1 amp 2 Drive LEDs The RED SCR Drive LEDs will turn on when the SCR drive output is on and increase in intensity as the power output is increased If the SCR gate is not wired properly or not connected the LED will not illuminate Because the drive signal varies considerably to give linear power output the LED should only be used as a rough indication of SCR Drive and not actual power output 4 11 3 Current Limit LED The RED Current Limit LED will illuminate when the current limit is actively limiting the load current 4 11 4 Load Fault LED Load detection requires a current transformer to be wired to the CT1 and CT2 terminals Copyright 2011 NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual The RED Load Fault LED will illuminate when an imbalance between the positive and negative half cycles exists or a shorted SCR is present
10. ensation increases stability of your process Configurable soft start soft change for high inrush loads Automatic 50 60Hz operation 47 to 63Hz Adjustable Voltage Limit Current feedback and Adjustable Current Limit Load and SCR fault Detection Drives SCR gates directly with DC drive Single phase and three phase control 3 Installation Safety Information Responsibility for determining suitability for use in any application equipment lies solely on the purchaser OEM and end user Suitability for use in your application is determined by applicable standards such as UL CUL and CE and the completed system involving this component should be tested to those standards WARNING FIRE HAZARD Even quality electronic components CAN FAIL KEEPING FULL POWER ON Provide a SEPARATE redundant OVER TEMPERATURE SHUTDOWN DEVICE to switch the power off if safe temperatures are exceeded Copyright 2011 NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual WARNING HIGH VOLTAGE This control module board has high voltage on it that can cause death This control must be installed in a GROUNDED enclosure by a qualified electrician in accordance with applicable local and national codes Including NEC and other applicable codes Provide a safety interlock on the door to remove power before gaining access to the device 3 1 Mounting Instructions The NWIPCM 1P mounts using six spacers or using nylon PCB clips such as Panduit CBLS50 C or Rich
11. ft Start can be set on or off using the configuration dipswitch 7 The default setting is off Soft start times below or above one second are available and can be ordered by adding a XSS to the ordering code where X is the time in seconds Soft Start Period 52 34 BMP pp Phot tt Mw The Soft Start ramps the voltage up slowly over the soft start period High Inrush Load soft Start used to limit the inrush Current Current Time Time 4 8 Voltage Limit The Voltage Limit feature is used in conjunction with the Line Voltage Compensation feature to limit the actual voltage delivered to the load The Voltage Limit is adjustable via the on board adjustment potentiometer For this feature to work properly Line Voltage Compensation must be turned on Switch 3 OFF This feature can be used without Line Voltage Compensation and will simply clip the command signal to a set level 4 8 1 Voltage Limit Adjustment Procedure Copyright 2011 NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual The Voltage Limit is adjustable from 0 to 100 of the max load voltage Setting the Voltage Limit potentiometer half way corresponds to a power limit of approximately 50 or a voltage limit of 70 of the max load voltage The best way to set the voltage limit is using a voltmeter connected across the load With the command input set to approximately 100 on startup turn the pot fully CCW Then just turn the pot CW until the desired output voltage is achie
12. hrough the resistor into the device resulting in high peak currents It is critically important when sizing your snubber to make sure that the resistor value does not become so low that the ratings of the SCR TRIAC are exceeded when the capacitor is discharged 3 3 4 MOVs and TVSs Copyright 2011 NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual Metal Oxide Varistors and Transient Voltage Suppressors are both used on TRIACS SCRs to clamp voltage spikes that can occur across the devices and damage them Snubbers are not a substitute for MOVs TVSs and vice versa Snubbers and MOVs TVs should be used together to get reliable performance and long life from the SCR TRIAC application External MOV must be installed across SCRs to limit peak voltages seen by the NWIPCM to 850VDC 3 4 Limited Warranty NuWave Technologies Inc warrant this product to be free from defect in workmanship and materials for a period of two 2 years from the date of purchase 1 Should unit malfunction return it to the factory If defective it will be repaired or replaced at no charge 2 There are no user serviceable parts on this unit This warranty is void if the unit shows evidence of being tampered with or subjected to excessive heat moisture corrosion or other misuse misapplication 3 Components which wear or damage with misuse are excluded e g relays 4 NuWave Technologies Inc shall not be responsible for any damage or losses however caused wh
13. ich may be experienced as a result of the installation or use of this product NuWave Technologies Inc liability for any breach of this agreement shall not exceed the purchase price paid E amp O E 4 Operation 4 1 Power Supply The NWIPCM 1P power supply requirement is 120 or 240VAC 10 47 63Hz The line synchronization for the phase angle firing is derived from the power supply input 4 2 Power Fusing A 500mA user serviceable fuse is provided Under normal circumstances this fuse should not open If it does it means that one of the following conditions exists 1 A large power line transient occurred 2 The NWIPCM 1P was wired incorrectly or the wrong line voltage unit was ordered 3 The NWIPCM 1P malfunctioned and requires service 4 3 Command Input The NWIPCM 1P can accept 4 20mA 0 10V 0 5V and Potentiometer and PWM inputs All analog commands are isolated from the power line and SCR drive outputs The type of command input can be configured via the dipswitch The default setting is O 5V potentiometer The PWM digital command input PLC Interface is isolated from the power line and SCR drive outputs but not from the other board I O Any leg of the command input can tolerate shorts to the OV input Connecting the power to any part of the command input or SCR drive outputs will cause damage to the unit 4 4 PWM Command Input Copyright 2011 NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual The NWIPCM 1P PWM Comm
14. rrent Retransmit SCR Drive Mains Isolation Copyright 2011 4 20mA 0 10V 0 5V Pot PWM 10K Q 0 10V 25040 4 20mA 100K 0 5V lt 50mS 10Hz 15KHz 5 VDC O 4mA or 24VDC O 10mA both non isolated 2 3VDC PWML terminal 5 2VDC PWMH terminal 3 5VDC PWML terminal 7 8VDC PWMH terminal 0 200mAAC 0 5VAC 1KQ 25KQ 2500Vrms 2500Vrms 1 98 power 2 10 10 up to 100 output 2 1 seconds to reach 100 output default 10 110 110 OFF 0 100 of max load voltage O to 50 C 120 or 240VAC 10 10 100MA max 47 to 63Hz Initial pulse peak current of 1 2A rise time of 200nS maintain current of 160mA See the SCR gate drive profile section for more detail 50mA 28VDC Max 0 5V 2 5K output impedance 2500Vrms NUWAVE TECHNOLOGIES INC NWIPCM 1P User Manual 7 3 1 Mechanical Dimensions 0 160 HOLE TYP 6 PLACES ev ar rautr ez Jeri Les 2998908 AC C21 4J7 00000 di H G e als As os o ERRE SE 39293310 Deo a8 O90 O o oF 220 o 0000000Dpy A oC13 gn Yo al loo Reo ol PWMS O A e 10 0 S lofo o Yo ys olU5Sio o UBlooo V olojo ojo o oo O Gw PWMF ooo ojoj o oo oF ul opo ojojo o oo o o o ojojo oo U4 o o ole oo o o Oo o o oo ell u2 _ o E o Be m O Lu ooono oeo DU o Estgen P 00000 Goes O OOOO 5 00 4 60 POWER NWIPCM 1 e A HAZARDOUS L120J 124093 1120 VOLTAGES LINE VOLTAGE SELECT p
15. ved For this feature to work as a true voltage limit it is important that the Line Voltage Compensation be enabled this is the OFF position of Switch 3 lf the line voltage compensation is set to OFF the voltage limit will act as a percentage of output limit and the absolute voltage limit will change with line voltage When the NWIPCM 1P is actively holding back or limiting the command via voltage limit the RED LIM ON LED will become energized 4 9 Current Feedback Current Limit When the Current Limit feature is enabled Dipswitch 8 set to on and the current transformer wired per the Current Transformer Input section the NWIPCM 1P will allow the maximum current to be set via the Current Limit Potentiometer The range of adjustment of the Current Limit potentiometer is 10 110 of full scale load current 110 OFF when the pot is turned fully clockwise The full scale load current is defined by the CT turns ratio described in the Current Transformer Input section 4 9 1 Current Transformer Input The NWIPCM 1P requires a current transformer to be wired to the CT1 and CT2 terminals to provide current feedback for the Current Limit and Load Fault detection features The CT input has a full scale of 200mA RMS and 5V peak For the best accuracy the current transformer turns ratio should be chosen according to the maximum current of the controlled load as follows CT Turns Ratio Max Measured Current full scale load
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